Transaxle for zero-turn vehicle

ABSTRACT

A zero turn vehicle is described. The vehicle comprises a frame, a prime mover, a transaxle, first and second gear boxes, first and second driven wheels, an operator foot platform, and an expansion tank. The transaxle is aft of the prime mover and has opposing first and second output shafts. The first and second gearboxes are respectively driven by and pivotable about the first and second output shafts. The first and second gear boxes respectively have first and second output axles aft of the first and second output shafts. The first and second driven wheels are respectively engaged with the first and second output axles. The operator foot platform is between the first and second gear boxes and aft of the transaxle. The expansion tank is between the transaxle and the operator foot platform and between the first and second gear boxes.

CROSS-REFERENCE

This application is a continuation of U.S. patent application Ser. No. 14/692,970, filed on Apr. 22, 2015, which claims the benefit of U.S. Provisional Application No. 61/982,785, filed on Apr. 22, 2014. The disclosures of both applications are incorporated herein by reference in their entirety.

BACKGROUND OF THE INVENTION

This invention relates to transaxles generally and, in particular, transaxles intended for use in zero turn vehicles and similar applications, and to the vehicles for use therewith.

SUMMARY OF THE INVENTION

Transaxles adaptable to various zero turn vehicle configurations, and the related vehicles, are disclosed herein.

A better understanding of the objects, advantages, features, properties and relationships of the invention will be obtained from the following detailed description and accompanying drawings which set forth illustrative embodiments that are indicative of the various ways in which the principles of the invention may be employed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partially schematic representation and partial cutaway of a zero turn vehicle having a transaxle adapted for use therein, the vehicle having several components removed for clarity.

FIG. 2 is a partially schematic representation of a zero turn vehicle having a transaxle similar to that of FIG. 1 adapted for use therein and several components removed for clarity.

FIG. 3 is a partially schematic representation and partial cutaway of another zero turn vehicle having a transaxle similar to that of FIG. 1 adapted for use with electronic controls, the vehicle having several components removed for clarity.

FIG. 4 is a partially schematic representation of another zero turn vehicle having a transaxle similar to that of FIG. 1 adapted for use with electronic controls and several components removed for clarity.

FIG. 5 is a partially schematic representation of another zero turn vehicle having a transaxle similar to that of FIG. 1 adapted for use therein and several components removed for clarity.

DETAILED DESCRIPTION OF THE DRAWINGS

The description that follows describes, illustrates and exemplifies one or more embodiments of the invention in accordance with its principles. This description is not provided to limit the invention to the embodiment(s) described herein, but rather to explain and teach the principles of the invention in order to enable one of ordinary skill in the art to understand these principles and, with that understanding, be able to apply them to practice not only the embodiment(s) described herein, but also any other embodiment that may come to mind in accordance with these principles. The scope of the invention is intended to cover all such embodiments that may fall within the scope of the appended claims, either literally or under the doctrine of equivalents.

It should be noted that in the description and drawings, like or substantially similar elements may be labeled with the same reference numerals. However, sometimes these elements may be labeled with differing numbers or serial numbers in cases where such labeling facilitates a more clear description. Additionally, the drawings set forth herein are not necessarily drawn to scale, and in some instances proportions may have been exaggerated to more clearly depict certain features. As stated above, this specification is intended to be taken as a whole and interpreted in accordance with the principles of the invention as taught herein and understood by one of ordinary skill in the art.

FIG. 1 depicts a first embodiment of a zero turn vehicle 100, which by way of example only is a stand-on mowing vehicle. Vehicle 100 has a frame 101 supporting a plate 102 upon which a prime mover 110, such as the illustrated internal combustion engine or an electric motor (not shown), can be mounted with its output shaft 111 extending downward therethrough. Below plate 102 is mounted a transaxle 140 whose input shaft 141 is powered by the output shaft 111 of prime mover 110 via a belt and pulley assembly 150. Frame 101 further supports a mowing deck 120, which may be of fixed height (relative to ground), ground-following, or height adjustable as known in the art. An operator's foot platform 130, situated by way of example only behind transaxle 140, is also affixed to frame 101. Foot platform 130 may be stationary or folding as known in the art. Frame 101 is supported above ground by a pair of caster wheel assemblies 116, 117 and a pair of driven wheels 118, 119.

Transaxle 140 provides rotational output to driven wheels 118, 119 through a pair of output shafts, 142, 143 which power a set of gear boxes 144, 145, respectively, having output axles 146, 147 rotationally driving a pair of wheel hubs 148, 149, respectively. Transaxle 140 has a single input shaft 141 that drives a pair of independent transmissions (not shown) disposed in a single housing 135, which may be of a hydrostatic, toroidal, friction or gear design. As illustrated, transaxle 140 is of a hydrostatic design, having an external expansion tank 155 for hydraulic fluid. A pair of control arms 162, 163 regulate the rotational speed and direction of output shafts 142, 143, which via gear boxes 144, 145 impart the final rotation speed and direction to driven wheels 118, 119, respectively. In a typical zero turn vehicle, such regulation controls steering of the vehicle, as the front caster wheel assemblies 116, 117 merely react in response to the actions of the rear driven wheels 318, 319. An example of how a hydrostatic transmission, via closed loop pump and motor operation, regulates such output is described in commonly owned U.S. Pat. No. 7,134,276, the terms of which are incorporated herein by reference in their entirety. The control arms 162, 163 are operator controlled via mechanical linkages to hand controls (not shown) in a known manner. Depending upon the transmission design, output shafts 142, 143 may extend directly from the main housing 135 of transaxle 140, or represent an intermediate shaft flexibly coupled to the outputs (not shown) of the transmission, such as by cardan shaft interface or the like.

Gear boxes 144, 145 can be fixedly mounted to frame 101, or suspended therefrom, whereby gear boxes 144, 145 are allowed to pivot about output shafts 142, 143 in a sealed fashion. These gear boxes 144, 145 are generally slender in design and may contain either a spur gear reduction or chain and sprocket reduction. Because of this slender gear box design, the generally U-shaped configuration of transaxle 140 permits foot platform 130 to be located closer to the main housing 135 of transaxle 140 per the vehicle designer's needs. FIG. 2 illustrates such an alternate position, with the foot platform 230 disposed between the gear boxes 244, 245. In addition, the relative position of the main housing 135 of transaxle 140 can be adjusted within the width (demarked as ‘A’ in FIG. 1) of frame 101, per the needs of the vehicle's designer, by configuring the relative lengths of the output shafts 142, 143.

FIG. 2 depicts an embodiment of a zero turn vehicle 200 similar to vehicle 100, but differing in that the main housing 235 of transaxle 240 is positioned adjacent gear box 245. As such, the right side output shaft (not shown) is substantially shorter than left side output shaft 242, which may be useful in accommodating other vehicle components. In addition, the main housing 235 of transaxle 240 is mounted to the upper surface of plate 202, akin to the mounting of prime mover 210, wherein transaxle input shaft 241 extends downward therethrough to permit proper alignment of belt and pulley assembly 250. Alternately, transaxle 240 may be mounted to additional vehicle frame features (not shown) above the plane of plate 202. Having a pivotable, sealed interface between transaxle output shaft 242 and gear box 244, on the left side for example, permits the necessary downward angling of gear box 244 from above plate 202 to properly align output axle 246 with driven wheel 218. Expansion tank 255 is disposed in front of transaxle 240.

FIG. 3 depicts an embodiment of a zero turn vehicle 300 similar to vehicle 100, but differing in that steering of vehicle 300 is accomplished electronically, via electric actuation of transmission control shafts (not shown). In the case of the previous embodiments, these control shafts were manipulated manually through operator linkages to the various control arms, 162, 163 and 262, 263 respectively. Electric actuators, such as the rotary actuators 372, 373 depicted in FIG. 3 are paired to the respective control shafts to similarly adjust the rotational speed and direction of output shafts 342, 343, and ultimately steered wheels 318, 319, respectively. Additionally, steering control can be added to caster wheel assemblies 316, 317 by means of a similar electric actuators 374, 375, respectively. Operator hand controls (not shown) communicate their relative positions to a controller 376 which coordinates the positioning of actuators 372, 373, 374, and 375 to improve the overall steering of vehicle 300. Front caster wheel assemblies 316, 317 are more immediately responsive to the actions of steered wheels 318, 319. A power source 380, such as a battery, alternator or generator, provides electric power to accomplish this coordinated steering control. As shown in FIG. 3, transaxle 340 includes a transaxle housing 335. As in the prior embodiments, prime mover 310 is disposed on plate 302, gear boxes 344 and 345 are disposed on frame 301, and as in the embodiment of FIG. 1, operator foot platform 330 is disposed on frame 301. Fluid expansion tank 355 is provided.

FIG. 4 depicts another configuration of a zero turn vehicle 400 in which a transaxle 440, similar in configuration to transaxles 140 and 340, having a single input shaft 441, a pair of independently controlled transmissions (not shown) in a single housing 435, and a pair of output shafts 442, 443 driven thereby, provide propulsion and steering to the vehicle 400. Similar to vehicle 300, the steering of vehicle 400 is electronically controlled.

Vehicle 400 differs from the previous embodiments in that the operator is carried in a seated position upon seat 432, and the prime mover 410 is mounted to vehicle frame 401 at the rear of the vehicle. As such belt and pulley assembly 450 takes on a unique orientation.

Vehicle 400 further differs from previous vehicle embodiments in that a steering wheel 490 provides operator steering inputs to a steering column 491 having a position sensor 492 in communication with controller 476. A forward/reverse operator control pedal, or rocker-style pedal 495, provides directional and speed inputs to the controller 476 via a position sensor (not shown). Controller 476, with power from power source 480, coordinates the positional adjustments of electric actuators 472, 473 on a pair of transmission control shafts (not shown) and the position adjustments of the electric actuators 474, 475 on the caster wheel assemblies 416, 417, respectively.

FIG. 5 depicts another vehicle 500 having a prime mover 510 and transaxle 540 configuration similar to vehicle 400, but varying in the manner in which the operator provides steering, speed and directional inputs to the vehicle 500. A pair of control sticks 594, 595, via mechanical linkages (not shown) to control arms 562, 563, respectively, independently provide speed and direction inputs to each of the driven wheels 518, 519, respectively. The operation of control arms 562, 563 in influencing the outputs of the independent transmissions contained within the main housing 535 of transaxle 540 is as previously described for transaxle 140. Similarly, the manner in which caster wheel assemblies 516, 517 react in response to the actions of the driven wheels 518, 519 is as described for vehicle 100. 

What is claimed is:
 1. A zero turn vehicle, the vehicle comprising: a prime mover supported on a frame; a transaxle supported on the frame aft of the prime mover, the transaxle comprising: a housing; an input shaft extending from the housing and driven by the prime mover, a first output shaft extending out of the housing; a second output shaft extending out the housing opposite the first output shaft; a first gear box driven by and pivotable about the first output shaft, the first gear box having a first output axle extending therefrom aft of the first output shaft; and a second gear box driven by and pivotable about the second output shaft, the second gear box having a second output axle extending therefrom aft of the second output shaft; first and second driven wheels respectively engaged with the first and second output axles; an operator foot platform having a defined area for supporting an operator of the vehicle, the operator foot platform being disposed on the frame aft of the transaxle, wherein the defined area is disposed entirely between a first vertical plane formed by an innermost surface of the first gear box and a second vertical plane formed by an innermost surface of the second gear box; and an expansion tank disposed on the vehicle between the transaxle and the operator foot platform and between the first gear box and the second gear box.
 2. The vehicle of claim 1, wherein the input shaft is driven by the prime mover via a belt and pulley assembly engaged with the prime mover and with the input shaft.
 3. The vehicle of claim 1, further comprising first and second caster wheels engaged with the frame opposite the operator foot platform.
 4. The vehicle of claim 3, further comprising: first and second electric actuators respectively engaged with the first and second caster wheels such that the first and second caster wheels are steerable; a controller disposed on the vehicle for controlling the first and second electric actuators; and a power source disposed on the vehicle to power the controller and the first and second electric actuators.
 5. The vehicle of claim 4, wherein the controller and the power source are located between the transaxle and the operator foot platform and between the first and second gear boxes.
 6. The vehicle of claim 1, further comprising: a first electric actuator engaged with the transaxle to control the first output shaft; a second electric actuator engaged with the transaxle to control the second output shaft; a controller disposed on the vehicle for controlling the first and second electric actuators; and a power source disposed on the vehicle to power the controller and the first and second electric actuators.
 7. The vehicle of claim 6, wherein the controller and the power source are located between the transaxle and the operator foot platform and between the first and second gear boxes.
 8. The vehicle of claim 1, wherein the operator foot platform is attached to the frame via a forward portion of the operator foot platform and an aft portion of the operator foot platform overhangs the frame.
 9. The vehicle of claim 1, wherein the operator foot platform pivots relative to the frame between an operating position and a storage position.
 10. A zero turn vehicle, the vehicle comprising: a prime mover supported on a frame; a transaxle supported on the frame aft of the prime mover, the transaxle comprising: a housing; an input shaft extending from the housing and driven by the prime mover, a first output shaft extending out of the housing; a second output shaft extending out of the housing opposite the first output shaft; a first gear box driven by the first output shaft and pivotably secured to the frame about the first output shaft, the first gear box having a first output axle extending therefrom aft of the first output shaft; and a second gear box driven by the second output shaft and pivotably secured to the frame about the second output shaft, the second gear box having a second output axle extending therefrom aft of the second output shaft; first and second driven wheels respectively engaged with the first and second output axles; and an operator foot platform comprising a horizontal flat plate for supporting an operator of the vehicle, the operator foot platform being disposed on the frame aft of the transaxle, wherein the horizontal flat plate is disposed entirely between an innermost surface of the first gear box and an innermost surface of the second gear box.
 11. The vehicle of claim 10, further comprising an expansion tank disposed between the transaxle and the operator foot platform.
 12. The vehicle of claim 10, wherein the housing of the transaxle is laterally offset relative to the frame.
 13. The vehicle of claim 12, wherein the second output shaft has a greater length than the first output shaft.
 14. The vehicle of claim 10, further comprising first and second caster wheels disposed on the frame forward of the prime mover.
 15. The vehicle of claim 14, further comprising: first and second electric actuators respectively engaged with the first and second caster wheels to steer the first and second caster wheels; a controller disposed on the frame to control the first and second electric actuators; and a power source on the frame to power the controller and the first and second electric actuators.
 16. The vehicle of claim 15, wherein the controller and the power source is disposed between the first and second gear boxes and between the transaxle and the operator foot platform.
 17. The vehicle of claim 16, wherein the operator foot platform is pivotable relative to the frame between an operating position and a storage position.
 18. A zero turn vehicle comprising: a prime mover supported on a frame; a transaxle supported on the frame aft of the prime mover, the transaxle comprising: an input shaft extending from a housing and driven by the prime mover, a first output shaft extending out of the housing; a second output shaft extending out the second side of the housing; a first gear box driven by the first output shaft and having a first outer surface and a first innermost surface, and a first output axle extending from the first outer surface aft of the first output shaft; and a second gear box driven by the second output shaft and having a second outer surface and a second innermost surface, and a second output axle extending from the second outer surface aft of the second output shaft; first and second driven wheels respectively engaged to the first and second output axles; and an operator foot platform for supporting an operator of the vehicle, the operator foot platform having a defined area and being disposed on the frame aft of the first and second output axles and wherein the defined area is disposed entirely between a first vertical plane formed by the first innermost surface of the first gear box and a second vertical plane formed by the second innermost surface of the second gear box.
 19. The vehicle of claim 18, wherein the frame comprises a plate having opposing top and bottom sides, the prime mover and the transaxle are mounted to the top side, and the first and second output axles are below the bottom side.
 20. The vehicle of claim 19, wherein the input shaft extends through the plate and is engaged to the prime mover via a belt and pulley assembly disposed below the bottom side. 